Removable Energy Storage Module for Industrial Controller Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial automation controllers face challenges in replacing back-up power sources, which are often integrated and inconvenient to switch or replace, especially in environments where battery replacement is not feasible, leading to potential safety issues and increased downtime.
Innovation Solution
A removable energy storage module with a back-up power source, such as a capacitor or battery, that can be selectively connected to the main module, allowing for easy replacement and ensuring safe and reliable operation by providing back-up power for emergency save operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the back-up power source is integrated into the controller module, then the reliability of the controller is improved, but the ease of replacement and adaptability deteriorate
Solution Approach 1:
The back-up power source is separated from the main controller module and placed in a removable energy storage module. This segmentation allows the power source to be easily replaced or swapped between different controller modules without affecting the controller's reliability, thus resolving the contradiction between integrated reliability and replaceability.
Solution Approach 2:
The removable energy storage module can be used with multiple different controller modules, providing universal applicability. This allows the same power source to serve multiple functions across different devices, improving adaptability while maintaining the reliability benefits of a dedicated power source.
2Reliability
If the back-up power source is integrated into the controller module, then the reliability is improved, but the ease of operation and replacement time deteriorate
Solution Approach 1:
By dividing the system into a removable energy storage module and a main controller module, the power source can be easily accessed, removed, and replaced without disassembling the controller. This segmentation directly improves ease of replacement while the modular design ensures the power source remains reliably integrated when attached.
Solution Approach 2:
The back-up power source is extracted from the permanent integrated position and placed in a removable module that can be easily taken out and replaced. This extraction allows for simple replacement operations while the module can be reattached to restore full functionality, maintaining reliability.
3Quantity of substance
If a battery is used as the back-up power source, then the energy storage capacity is improved, but the adaptability to different environments deteriorates
Solution Approach 1:
The removable energy storage module can accommodate different types of power sources (batteries, capacitors) and be used across multiple controller modules and environments. This universality allows the system to adapt to different environmental requirements while maintaining sufficient energy storage capacity through appropriate power source selection.
Solution Approach 2:
The system allows dynamic selection and replacement of different energy storage technologies based on environmental conditions. Users can switch between battery-based and capacitor-based solutions depending on temperature, safety requirements, or application needs, thus improving environmental adaptability while maintaining energy storage capacity.
4Object-affected harmful factors
If the controller must be powered down for battery replacement, then the safety is improved, but the loss of time increases
Solution Approach 1:
The removable energy storage module allows battery replacement without requiring the controller to be powered down. The modular design enables safe replacement operations to continue while the controller remains operational, eliminating downtime while maintaining safety through proper isolation procedures.
Solution Approach 2:
The controller can continue operating while the battery is being replaced in the removable module. This continuity of useful action eliminates the need to power down the controller during maintenance, reducing downtime while safety protocols are maintained through proper electrical isolation during the replacement process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables safe and efficient replacement of back-up power sources without powering down the controller, reducing downtime and ensuring reliable operation by allowing for easy switching between different energy storage types, thus improving the operational flexibility and safety of industrial automation controllers.
Implementation Method 1
The back-up power source can be, e.g., a battery or a capacitor
Implementation Method 2
A capacitor back-up power source 28 can alternatively be used
Data Source
AI summary
An industrial automation controller module includes a main module and an energy storage module (ESM) releasably connected to the main module. The ESM includes a back-up electrical power source such as a battery or a capacitor that is electrically connected to processor circuitry of the main module when the ESM is physically connected to the main module. In case of interruption of operating power to the processor circuitry of the main module, the back-up power source of the ESM supplies back-up power to the main module to allow for completion of an emergency save operation to save data to non-volatile memory in the main module. If the ESM includes a capacitor back-up power source, it is charged by the main module and the capacitor charge is dissipated if the ESM is separated from the main module. In all cases, the ESM can include one or more configuration parameters stored therein that allow the main module to validate (or not) the ESM for the requirements of the main module, with respect to type of back-up power source, product code or model, capacity of back-up power source, and the like. The main module can also initiate periodic testing of the back-up power source of the ESM.